Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology最新文献_第3页

Assessing drivers of measurement errors in industrial processes: A multivariate decision-making method based on customer preferences 评估工业过程中测量误差的驱动因素：基于客户偏好的多变量决策方法

IF 3.7 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology

Pub Date : 2026-01-01 DOI: 10.1016/j.precisioneng.2026.01.001

Matheus C. Almeida , Michele S. Carmelossi , Lucas G. Oliveira , José Henrique F. Gomes , Rogério S. Peruchi

In industrial processes, reliable measurement systems are fundamental for effective quality control and decision-making. This study addresses the challenge of integrating decision-maker customer preferences into multivariate measurement system analysis, focusing on repeatability and reproducibility indices (%R&R), especially in contexts where correlated quality characteristics are involved. Traditional approaches in Measurement System Analysis often neglect the varying importance of quality characteristics or their interdependencies, which can hinder accurate decision-making. To overcome these limitations, the article proposes a novel methodology based on Weighted Principal Components and prioritization of quality characteristics according to their significance. Through numerical simulations and real data from an industrial stainless steel cladding process, the proposed method is validated across 18 scenarios, highlighting how assigning varying weights to characteristics impacts multivariate R&R indices. The findings reveal that prioritization alters the system's classification, aligning it with the most significant variables while also capturing correlations among characteristics. When 90 % of the weight was assigned to a single characteristic, the multivariate R&R index closely followed its univariate counterpart, whereas with 47.5 % distributed between two characteristics, the multivariate index assumed intermediate values. Furthermore, by adjusting priorities in a real industrial measurement system, the proposed method significantly enhanced measurement accuracy, reducing the multivariate %R&R index from 8.98 % (marginal classification) to 0.76 % (acceptable classification)—a 91.5 % reduction in measurement system variability.

在工业过程中，可靠的测量系统是有效的质量控制和决策的基础。本研究解决了将决策者客户偏好整合到多元测量系统分析中的挑战，重点关注可重复性和再现性指数（%R&；R），特别是在涉及相关质量特征的情况下。传统的测量系统分析方法往往忽略了质量特征的不同重要性或它们之间的相互依赖性，这可能会妨碍准确的决策。为了克服这些局限性，本文提出了一种基于加权主成分和质量特征按重要性排序的新方法。通过数值模拟和工业不锈钢包覆过程的实际数据，该方法在18种情况下进行了验证，突出了为特征分配不同权重如何影响多元R&；R指标。研究结果表明，优先级改变了系统的分类，使其与最重要的变量保持一致，同时也捕获了特征之间的相关性。当90%的权重分配给单一特征时，多变量r&r指数紧跟其单变量对应项，而当47.5%的权重分配在两个特征之间时，多变量指数假设中间值。此外，通过调整实际工业测量系统中的优先级，所提出的方法显着提高了测量精度，将多变量R&；R指数从8.98%（边际分类）降低到0.76%（可接受分类）-测量系统可变性降低了91.5%。

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引用次数: 0

Mid-spatial-frequency waviness in ultra-precision machining: Real-time trajectory analysis of three machine tools 超精密加工中的中频波动：三台机床的实时轨迹分析

IF 3.7 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology

Pub Date : 2025-12-30 DOI: 10.1016/j.precisioneng.2025.12.019

Yan Wei , Masahiro Takeda , Takuya Hosobata , Yutaka Yamagata , Shinya Morita

Mid-spatial-frequency (MSF) waviness — typically characterized by waviness with spatial period ranging from 0.1 mm to several millimeters — significantly impacts the optical performance of precision optics. In diamond-machined optical surfaces, trajectory variations of the machine tool can induce MSF waviness that are difficult to eliminate through conventional polishing due to their spatial frequency range. It is therefore crucial to measure and compensate for machine tool control error in real-time during the cutting process. To address this issue, we developed a real-time position capturing system (RPCS) to assess the control errors of three types of ultra-precision machine tools, with programming resolutions on linear axes ranging from 10 nm to 0.1 nm. First, we evaluated the profile accuracy of optical flat and spherical mirror on each machine tool using on-machine measurement (OMM) with a laser confocal probe, to verify linear motion accuracy. Subsequently, we manufactured three plano-elliptic optical surfaces — intended for neutron-focusing mirrors — using the respective machine tools. We then analyzed the MSF waviness of the machined mirrors and correlated it with the motion errors captured by the RPCS. Our results revealed that the machine equipped with oil hydrostatic guideways exhibited a control error of approximately 100 nm and produced MSF waviness with an amplitude around 10 nm. In contrast, machines with V–V roller guideways demonstrated significantly lower MSF amplitudes, below 10 nm. These findings demonstrate a clear correlation between guideway structure, trajectory stability, and MSF waviness, providing valuable insights for improving the precision of optics fabrication.

中空频（MSF）波浪度对精密光学系统的光学性能影响很大，其特征是空间周期在0.1 mm到几mm之间。在金刚石加工的光学表面中，机床的轨迹变化会引起MSF波纹，由于其空间频率范围，难以通过常规抛光消除。因此，在切削过程中对机床控制误差进行实时测量和补偿是至关重要的。为了解决这个问题，我们开发了一个实时位置捕获系统（RPCS）来评估三种超精密机床的控制误差，其线性轴上的编程分辨率从10 nm到0.1 nm不等。首先，我们利用激光共聚焦探针对每台机床上的光学平面镜和球面镜的轮廓精度进行了评估，以验证直线运动精度。随后，我们使用各自的机床制造了三个用于中子聚焦镜的平椭圆光学表面。然后，我们分析了加工后反射镜的MSF波度，并将其与RPCS捕获的运动误差相关联。结果表明，采用油液静压导轨的机床控制误差约为100 nm，产生的MSF波幅约为10 nm。相比之下，采用V-V滚轮导轨的机器显示出明显较低的MSF振幅，低于10 nm。这些发现表明导轨结构、轨迹稳定性和MSF波浪度之间存在明显的相关性，为提高光学制造精度提供了有价值的见解。

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引用次数: 0

Optimization of multi-bolt assembled precision optical mirrors considering non-ideal mating surfaces 考虑非理想配合面的多螺栓装配精密光学反射镜优化

IF 3.7 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology

Pub Date : 2025-12-29 DOI: 10.1016/j.precisioneng.2025.12.018

Hongda Shen , Kang Li , Runxia Zhang , Huanxiong Xia , Jianhua Liu , Xuerui Zhang , Guorui Zhang , Xin Liu

Non-ideal surface mating with multiple bolts is an important assembly structure in precision optical mirrors. However, determining the optimal torque for each bolt under the non-ideal contact of structural mating surfaces remains challenging. This paper develops an integrated optimization strategy that synergizes experimental analysis, finite element modeling, and intelligent algorithms to address this challenge. Mirror assembly experiments show that both non-ideal morphology and bolt torque significantly affect assembly accuracy. Simulations reveal non-uniform contact pressure arising from non-ideal surface morphology during assembly. A Genetic Algorithm-Backpropagation (GA-BP) neural network mapping bolt torque to assembly accuracy is integrated with a genetic algorithm to determine the optimal torque configuration. Experimental and numerical validations confirm the strategy's efficacy, achieving an average reduction in assembly-induced surface-figure Root Mean Square (RMS) of 36.09 %. The proposed approach provides a practical solution for the precision assembly of multi-bolt structures, effectively mitigating the adverse effects of non-ideal mating surfaces.

非理想面多螺栓配合是精密光学反射镜的重要装配结构。然而，在结构配合面非理想接触下，确定每个螺栓的最佳扭矩仍然是一个挑战。本文开发了一种综合优化策略，将实验分析、有限元建模和智能算法相结合，以应对这一挑战。镜体装配实验表明，非理想形貌和螺栓扭矩对镜体装配精度有显著影响。模拟结果表明，由于装配过程中表面形貌不理想，导致接触压力不均匀。将遗传算法-反向传播（GA-BP）神经网络映射螺栓扭矩到装配精度，并结合遗传算法确定最佳扭矩配置。实验和数值验证证实了该策略的有效性，使装配引起的表面图形均方根（RMS）平均降低36.09%。该方法为多螺栓结构的精密装配提供了一种实用的解决方案，有效地减轻了非理想配合面的不利影响。

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引用次数: 0

A study of flatness digital measuring instrument models for algorithmic validation of minimum zone method 最小区法算法验证的平面度数字测量仪模型研究

IF 3.7 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology

Pub Date : 2025-12-23 DOI: 10.1016/j.precisioneng.2025.12.010

Keying Yang, Hang Yu, Ming Kong, Jing Yu

To address the current lack of standardized evaluation systems and complete metrological traceability chains for flatness assessment algorithms, this study proposes a flatness digital measuring instrument model based on the minimum zone (MZ) method. By combining triangle and cross criteria, along with point cloud geometric feature analysis, barycentric coordinate methods, and projection techniques, a constraint framework satisfying the four fundamental sampling points is established. Based on rigorous mathematical and geometric derivations, a unified standard for constructing the flatness digital measuring instrument model is developed, and sampling procedures as well as reference model examples under different criteria are provided. Utilizing this model set and its implementation methodology, a series of validation experiments were conducted to assess the feasibility and applicability of various flatness evaluation algorithms and measurement software. Experimental results demonstrate that the proposed model is effective for verifying and evaluating flatness assessment algorithms, supporting accuracy validation down to 0.1 μm. This research provides a reproducible and traceable technical pathway for the standardized verification of flatness algorithms, supporting quality control in ultra-precision manufacturing.

针对目前平面度评估算法缺乏标准化的评估体系和完整的计量溯源链的问题，本研究提出了一种基于最小区域（MZ）方法的平面度数字测量仪模型。结合三角准则和交叉准则，结合点云几何特征分析、质心坐标法和投影技术，建立了满足四个基本采样点的约束框架。在严格的数学和几何推导的基础上，建立了平面度数字测量仪模型的统一标准，并给出了不同标准下的采样步骤和参考模型实例。利用该模型集及其实现方法，进行了一系列验证实验，以评估各种板形评价算法和测量软件的可行性和适用性。实验结果表明，该模型能够有效地验证和评估平面度评估算法，支持精度低至0.1 μm的验证。该研究为平面度算法的标准化验证提供了可重复和可追溯的技术途径，为超精密制造中的质量控制提供了支持。

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引用次数: 0

Achieving sub-μm accuracy on a pagoda-type micro-CMM via dynamic volumetric error compensation 通过动态体积误差补偿，在宝塔式微型三坐标测量机上实现亚μm精度

IF 3.7 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology

Pub Date : 2025-12-23 DOI: 10.1016/j.precisioneng.2025.12.016

Ya-Xiong He , Yefeng Chen , Zai Luo , Dian Bian , Yinbao Cheng , Wensong Jiang , Yaru Li , Rui-Jun Li

The increasing demand for inspecting complex micro-structures challenges conventional metrology, driving the need for 3D coordinate measuring systems with micro- and nano-scale accuracy. This paper presents a volumetric error compensation approach to achieve sub-micrometer accuracy metrology by developing a global and dynamic error compensation model on the basis of Abbe principle and Bryan principle. A comprehensive volumetric error model for general CMMs incorporating all 21 geometric errors was derived from the fundamental Abbe and Bryan principles using kinematics of rigid bodies. The general model was then applied and simplified for a self-developed Pagoda-type micro-CMM equipped with integrated multi-degree-of-freedom sensors for instantaneous geometric error measurement. The efficacy of the volumetric error compensation was validated through single-axis positioning tests, gauge block measurements, and the inspection of complex micro-structures, including a bearing raceway and a high-aspect-ratio micro-hole. After dynamic volumetric error compensation, the positioning errors in three directions were reduced from a maximum of 130 nm to below 10 nm. Volumetric accuracy tests on gauge blocks showed a reduction in the standard deviation of length measurements by 73 % (X-axis), 55 % (Y-axis), and 75 % (Z-axis). The compensated system successfully measured a bearing's inner raceway with a radius standard deviation of 161 nm and a high-aspect-ratio (5:1) micro-hole with a maximum diameter standard deviation of 48 nm, achieving an expanded measurement uncertainty of 155 nm (k = 2).

对复杂微结构检测的需求日益增长，对传统计量学提出了挑战，推动了对具有微纳米级精度的三维坐标测量系统的需求。在Abbe原理和Bryan原理的基础上，建立了一种全局动态误差补偿模型，提出了一种实现亚微米精度测量的体积误差补偿方法。利用刚体运动学原理，从Abbe和Bryan的基本原理出发，导出了包含所有21种几何误差的通用三坐标测量机的综合体积误差模型。将该模型应用于自行研制的集成多自由度传感器的宝塔式微型三坐标测量机，并进行了简化。通过单轴定位试验、量块测量以及对轴承滚道和高纵横比微孔等复杂微结构的检测，验证了体积误差补偿的有效性。经过动态体积误差补偿后，三个方向的定位误差从最大130 nm减小到10 nm以下。量块的体积精度测试表明，长度测量的标准偏差减少了73% （x轴），55% （y轴）和75% （z轴）。补偿系统成功测量了半径标准差为161 nm的轴承内滚道和最大直径标准差为48 nm的高纵横比（5:1）微孔，实现了155 nm （k = 2）的扩展测量不确定度。

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引用次数: 0

Comprehensive coupled wear-vibration analysis of roller linear guide considering multi-stage and multi-state actual contact variation 考虑多阶段多状态实际接触变化的滚子直线导轨磨损-振动综合耦合分析

IF 3.7 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology

Pub Date : 2025-12-22 DOI: 10.1016/j.precisioneng.2025.12.017

Tian-Wen Qi , Sheng-Hao Xu , De-Jun Cheng , Xue Zuo

Wear-induced stiffness variation in roller linear guides (RLGs) decreases their dynamic load-bearing stability and leads to significant positioning errors. However, most existing models assume uniform wear at the roller-raceway interfaces within idealized contact zones, which greatly limits dynamic performance analysis accuracy. This paper investigates the relationships among contact load, impact angle, and elastic deformation during a multi-stage contact-variation process associated with uneven wear evolution. Based on this analysis, it proposes a novel physics-based predictive wear model to determine the actual uneven wear-depth distribution and the corresponding contact zones between the carriage and rail raceways. Subsequently, a comprehensive wear-vibration coupling model is developed to analyze the wear-induced five-degree-of-freedom (5-DOF) dynamic behavior under multidirectional loading conditions, based on a mechanic model that accurately describes preload degradation in multi-state contact interfaces. Furthermore, numerical simulations are conducted to evaluate the uneven wear-depth distribution, preload degradation, and nonlinear dynamic characteristics. Moreover, the proposed method is compared with existing models. The findings demonstrate the superior performance of the proposed approach and show that it can accurately predict the actual wear-depth distribution and vibration behavior of RLG systems.

滚子直线导轨的磨损刚度变化会降低其动承载稳定性，导致定位误差显著。然而，现有模型大多假设理想接触区域内滚子滚道界面磨损均匀，这极大地限制了动态性能分析的准确性。本文研究了非均匀磨损多阶段接触变化过程中接触载荷、冲击角和弹性变形之间的关系。在此基础上，提出了一种新的基于物理的预测磨损模型，以确定车厢与轨道之间的实际不均匀磨损深度分布和相应的接触区域。随后，基于准确描述多状态接触界面预紧力退化的力学模型，建立了多向加载条件下的磨损-振动综合耦合模型，分析了多向加载条件下的磨损五自由度动力学行为。在此基础上，进行了数值模拟，分析了非均匀磨损深度分布、预紧力退化和非线性动态特性。并与现有模型进行了比较。研究结果证明了该方法的优越性，并表明该方法可以准确预测RLG系统的实际磨损深度分布和振动行为。

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引用次数: 0

A self-initialized one-dimensional measuring machine for calibrating the length of a ball bar 一种自初始化的用于校准钢条长度的一维测量机

IF 3.7 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology

Pub Date : 2025-12-20 DOI: 10.1016/j.precisioneng.2025.12.015

Yuan Liu, Jingru Wang, Haojie Xia, Jin Zhang, Weishi Li

Ball bars are a type of length artifacts generally used in the performance verification of coordinate measuring machines. This paper presents a one-dimensional measuring machine (1-DMM) for calibrating the length of a ball bar, proposing a method for initializing the 1-DMM with two uncalibrated ball bars. The length of the ball bar calibrated with the 1-DMM is directly traceable to the laser wavelength. The 1-DMM is designed according to Abbe’s principle, and the measurement range of the proposed 1-DMM is from

200 mm

to

2000 mm

, with expanded uncertainty of

\sqrt{0.23 L^{2} - 0.85 L + 1.61} μ m

, where

L

is given in meters. When measuring a ball bar with a length longer than

1.1 m

, the uncertainty of the proposed 1-DMM is smaller than the expanded uncertainty of the existing 1-DMMs and the M48 CMM of NIST.

球杆是三坐标测量机性能检定中常用的一种长度工件。本文介绍了一种用于标定钢条长度的一维测量机（1-DMM），并提出了一种用两个未标定钢条初始化1-DMM的方法。用1-DMM校准的球杆长度可直接追溯到激光波长。1-DMM根据Abbe原理设计，所提出的1-DMM测量范围为200mm ~ 2000mm，扩展不确定度为0.23L2−0.85L+1.61μm，其中L的单位为米。在测量长度大于1.1m的球杆时，所提出的1-DMM的不确定度小于现有1-DMM和NIST M48 CMM的扩展不确定度。

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引用次数: 0

An accumulative wear prediction method of planetary roller screw mechanism with multi-source errors 多源误差行星滚子丝杠机构累积磨损预测方法

IF 3.7 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology

Pub Date : 2025-12-17 DOI: 10.1016/j.precisioneng.2025.12.014

Mingcai Xing , Shuo Liu , Mingkang Wang , Yi Cui , Qiangqiang Huang , Songyu Li

During the machining process of planetary roller screw mechanism (PRSM), the multiple geometrical errors are produced and the multiple errors play the significant roles in wear evolution of PRSM. However, the accumulative wear evolution of PRSM with multi-source errors has remained unclear. This work proposes the accumulative wear prediction model of PRSM with multi-source errors. The accumulative wear evolution of screw, rollers and nut with multi-source errors are elucidated based on the measuring roller nominal diameter error (RNDE), screw eccentric error (SEE) and nut eccentric errors (NEE). The comprehensive effects of RNDE, SEE and NEE on the accumulative wear evolution of PRSM are investigated. It is found that the multi-source errors cause the inconsistency in the accumulative wear depth among multiple rollers, and the reasonable errors matching can reduce the accumulative wear of nut.

行星滚子螺杆机构在加工过程中产生多种几何误差，这些几何误差对行星滚子螺杆机构的磨损演化有重要影响。然而，PRSM在多源误差情况下的累积磨损演化尚不清楚。提出了含多源误差的永磁同步电机累积磨损预测模型。基于测量滚轮公称直径误差（RNDE）、螺杆偏心误差（SEE）和螺母偏心误差（NEE），分析了多源误差下螺杆、滚子和螺母的累积磨损演化规律。研究了RNDE、SEE和NEE对PRSM累积磨损演化的综合影响。发现多源误差导致多滚子累积磨损深度不一致，合理的误差匹配可以减少螺母累积磨损。

引用次数: 0

Collaborative control of surface quality and stability in hemispherical resonator grinding 半球形谐振腔磨削表面质量与稳定性的协同控制

IF 3.7 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology

Pub Date : 2025-12-13 DOI: 10.1016/j.precisioneng.2025.12.013

Jiangang Sun , Henan Liu , Biao Qin , Jian Cheng , Mingjun Chen

During the grinding of hemispherical resonator and other hard-brittle complex curved components, variations in geometric features lead to changes in contact conditions and force states, inducing non-uniform wheel wear and resulting in fluctuations in workpiece surface quality. Previous studies have indicated that grinding parameters are key factors influencing surface integrity and wheel wear behavior in the machining of hard-brittle materials. Building on this understanding, an optimization strategy centered on the grinding ratio is proposed herein for the first time to achieve simultaneous improvement of workpiece surface quality and wheel lifespan. Initially, a correlation model between grinding parameters and the grinding ratio was established using multiple linear regression and analysis of variance, revealing the evolution of wheel wear behavior and workpiece surface integrity under different grinding ratio conditions. Furthermore, a multi-objective optimization model tailored for hemispherical resonator was formulated, and the non-dominated sorting genetic algorithm (NSGA-II) combined with the ideal distance method was employed to determine the optimal grinding parameters. Experimental results demonstrate that, following optimization, hemispherical resonator surface roughness can be maintained within 68.90–76.94 nm, representing an improvement of 21.62 %–37.05 % compared with conventional grinding parameters, while the fluctuation range decreased by 33.14 %. Moreover, under the same material removal volume, wheel wear was reduced by 16.07 %–35.14 %. The proposed grinding ratio–centered optimization framework provides a theoretical basis for achieving high-quality and stable machining of hard-brittle complex curved components while extending wheel lifespan.

在半球形谐振器等硬脆复杂曲面部件的磨削过程中，几何特征的变化导致接触条件和受力状态的变化，导致砂轮磨损不均匀，工件表面质量波动。以往的研究表明，磨削参数是影响硬脆材料加工表面完整性和砂轮磨损行为的关键因素。在此基础上，首次提出了一种以磨削比为中心的优化策略，以实现工件表面质量和砂轮寿命的同步提高。首先，通过多元线性回归和方差分析，建立了磨削参数与磨削比之间的相关模型，揭示了不同磨削比条件下砂轮磨损行为和工件表面完整性的演变规律。在此基础上，建立了针对半球形谐振腔的多目标优化模型，采用非支配排序遗传算法（NSGA-II）结合理想距离法确定了最优磨削参数。实验结果表明，优化后的半球形谐振腔表面粗糙度可保持在68.90 ~ 76.94 nm范围内，比常规磨削参数提高21.62% ~ 37.05%，波动幅度减小33.14%。在相同材料去除率下，砂轮磨损量降低了16.07% ~ 35.14%。提出的以磨削比为中心的优化框架为实现硬脆复杂曲面零件的高质量稳定加工和延长车轮寿命提供了理论依据。

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引用次数: 0

Design of multi-electrode synchronized electrochemical trepanning with rotational feeding system for inner twisted blisk 内扭盘片多电极同步电化学钻孔旋转送料系统设计

IF 3.7 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology

Pub Date : 2025-12-13 DOI: 10.1016/j.precisioneng.2025.12.011

Erhao Jiao, Dong Zhu, Yunmiao Wang, Ruolong Wang

As a core component of aero-engine compressor, inner twisted blisk features confined internal spaces, numerous blades with complex twisted surfaces, which is difficult to manufacture and improve machining efficiency. Electrochemical trepanning (ECTr) is a specialized electrochemical machining (ECM) method offering advantages such as easily controllable flow fields and high machining flexibility. However, machining efficiency is limited by the widespread adoption of the single-blade machining mode in current ECTr. Therefore, this paper proposed a multi-electrode synchronized electrochemical trepanning (MES-ECTr) with rotational feeding method, and established a MES-ECTr with rotational feeding device to realize the synchronized machining of multiple inner twisted blades in a single feed operation. The parameters such as the layout, quantity and diameter of ball bearings in the rotational feeding module were optimized through fluid-structure interaction (FSI) simulation, and the reliability of the device were improved. Furthermore, to improve machining stability for multiple blades, a multi-channel electrolyte control (MC-EC) platform was established to monitor and regulate the electrolyte flow of multiple channels in real-time, thereby enhancing flow field uniformity. Finally, the MES-ECTr with rotational feeding experiments were conducted. Stable synchronized machining of three inner twisted blades was achieved at 18 V machining voltage and 1.5 mm/min feed rate, with excellent surface consistency and accuracy consistency. Compared to conventional single-blade mode, machining efficiency improved by 226 %, demonstrating the effectiveness of the designed MES-ECTr with rotational feeding system and its promising application prospects.

内扭盘是航空发动机压气机的核心部件，其内部空间狭小、叶片数量众多、扭面复杂，制造难度大，难以提高加工效率。电化学钻孔加工（ECTr）是一种特殊的电化学加工（ECM）方法，具有流场易于控制和加工灵活性高等优点。然而，目前ECTr普遍采用单刀片加工方式，限制了加工效率。因此，本文提出了一种旋转进给的多电极同步电化学钻削（MES-ECTr）方法，并建立了一种旋转进给的MES-ECTr装置，实现了一次进给操作中多个内扭叶片的同步加工。通过流固耦合（FSI）仿真，优化了旋转进给模块中滚珠轴承的布置、数量和直径等参数，提高了装置的可靠性。为提高多叶片的加工稳定性，建立了多通道电解液控制（MC-EC）平台，实时监测和调节多通道电解液流动，增强流场均匀性。最后，进行了MES-ECTr旋转进料实验。在18 V的加工电压和1.5 mm/min的进给速度下，实现了三片内扭叶片的稳定同步加工，具有良好的表面一致性和精度一致性。与传统的单刀片模式相比，加工效率提高了226%，证明了旋转进给系统MES-ECTr的有效性和广阔的应用前景。

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引用次数: 0